Contents

Foreword

Operating instructions

Maintenance

• Car care
• Starting the engine using a booster battery
• Vehicle towing
• Jacking up the car
• Maintenance - list of works
• Maintenance - works
• Engine compartment - visual inspection
• Engine oil and oil filter - change
• Coolant - check level
• Ribbed belt - condition check
• Exhaust system - visual inspection
• Spark plugs - removal and installation
• Fuel filter - removal and installation
• Air filter - replacing the filter element
• Transmission. Main gear
• Gearbox - visual leak check
• Suspension and steering
• Steering cuffs - check
• Ball joint caps - check
• Power steering fluid level check
• Rear suspension trailing arm support backlash - check
• Brakes, tires, wheels
• Brake fluid - check level
• Brake pads - checking residual thickness
• Drum brake pads - checking residual thickness
• Parking brake - functional check, running-in and adjustment
• Brake fluid - replacement
• Wheels and tires
• Body. Salon equipment. Heater
• Seat belts - visual inspection
• Dust / combination filter - change
• Trailer hitch - check, clean, lubricate
• Electrical equipment
• Windshield wipers - checking the rubber bands of the brushes
• Battery - checking electrolyte level
• Service warning and control device - entering the next service period

Engine

• Specifications
• General information
• Vehicle and engine identification
• Engine - removal and installation
• Cylinder head - removal and installation
• Cylinder head cover - removing and installing
• Ribbed belt - removal and installation
• Engine - start
• Engine lubrication system
• Oil - circulation
• Oil pressure - check
• Oil level sensor - removal and installation
• Oil pan - removal and installation

Cooling, heating and ventilation system

• Engine cooling system
• Coolant
• Coolant - replacement
• Thermostat - removal and installation
• Thermostat - check
• Checking the tightness of the cooling system
• Water pump - removal and installation
• Radiator blower fan - removal and installation
• Radiator - removal and installation
• Heating and air conditioning
• Air deflectors - removal and installation
• Heater / air conditioner switches - removal and installation
• Illumination lamp on the air conditioner temperature switch - removal and installation
• Heater fan motor - removal and installation
• Additional resistance of the interior blower fan - removal and installation

Fuel injection system - gasoline engines

• General description and precautions
• The principle of operation of the fuel injection system
• Fuel injectors - check
• Fuel rail - removal and installation
• Engine control unit emergency program function

Power system - diesel engines

• How a diesel engine works
• Glow plugs - check
• Glow plugs - removal and installation
• Fuel injectors - removal and installation

Fuel system

• General provisions
• Fuel system - pressure relief
• Fuel pump and fuel gauge sensor - removal and installation
• Fuel pump - removal and installation
• Fuel cutoff solenoid valve - removal and installation
• Air filter - removal and installation
• Accelerator pedal stop - adjustment
• Intake manifold - removal and installation
• Intake manifold module - removal and installation
• Crankshaft position sensor - removing and installing software
• Camshaft position sensor - removal and installation install

Exhaust system

• General information
• How the catalyst works
• Exhaust turbocharger
• Downpipe with catalyst - removal and installation
• Downpipe with main muffler - removal and installation
• Lambda probe - removal and installation
• Front catalytic converter - removing and installing
• Rear catalyst and main muffler - removal and installation
• Turbocharger - removal and installation

Ignition system

• General description
• Spark plugs - removal and installation

Clutch

• General description
• Coupling - removal, installation and inspection
• Clutch actuator - bleeding and hydraulic fluid change
• Automatic clutch

Mechanical and automatic transmissions

• Specifications
• Manual transmission
• Gear shift mechanism - removal and installation
• Clutch - removal and installation
• Differential, input and output shafts - removal and installation
• Automatic transmission - removal and installation
• Gear selector cable - removal and installation
• Parking lock mechanism - removal and installation
• Gear selector cable - adjustment

Braking system

• Specifications
• General description
• Disc brake pads - removal, inspection and installation
• Caliper - removal and installation
• Front wheel brake disc - removal and installation
• Rear wheel brake disc - removal and installation
• Brake disc - check
• Parking brake pads - removal and installation
• Parking brake - adjustment
• Parking brake cable - removal and installation
• Drum brake pads - removal and installation
• Brake fluid
• Brake system - bleeding
• Brake hoses - removal and installation
• Vacuum brake booster - check
• Brake light switch - removal and installation
• Parking brake warning light switch - removal and installation

Suspension and steering

• General information
• Front suspension
• Suspension strut - removal and installation
• Shock strut - disassembly
• Shock absorber - check
• Front axle beam - removal and installation
• Drive shafts - removal and installation
• CV joint seals - removal and installation
• Rear suspension
• Rear suspension shock absorber - removal and installation
• Rear suspension spring - removal and installation
• Lower trailing arm - removal and installation
• Crossbeam shank flange - removal and installation
• Steering
• Airbags - precautions
• Steering wheel airbag assembly - removal and installation
• Steering wheel - removal and installation
• Contact spiral - removal and installation
• Tie rod end - removal and installation
• Steering sleeve - removing and installing

Body and interior trim

• Interior trim
• Cars from 10/97 to 2/01
• Driver's side deflector cover - removal and installation
• Glove box - removal and installation
• Driver side instrument panel lower cover - removal and installation
• Center console cover - removing and installing
• Front part of the center console - removal and installation
• Rear part of the center console - removal and installation
• Gear lever cover - removal and installation
• Ashtray on the center console - removal and installation
• Front pillar trim - removal and installation
• Cars of release from 3/01
• Glove box - removal and installation
• Glove cover - removing and installing
• Driver's side instrument panel lower trim - removal and installation
• Center console cover - removing and installing
• Front part of the center console - removal and installation
• Ashtray on the center console - removal and installation
• Rear part of the center console - removal and installation
• Front pillar trim - removal and installation
• Dashboard - removal and installation
• Cars from 10/97 year
• Interior rearview mirror - removal and installation
• Front seat - removal and installation
• Armrest above center console - removal and installation
• Additional brake light cover - removal and installation
• Rear headliner trim - removal and installation
• Body. General description and precautions
• Mudguard (protection) underbody - removal and installation
• Front bumper - removal and installation
• Rear bumper - removal and installation
• Protective pads for bumpers - removal and installation
• Front wheel arch liner - removal and installation
• Rear wheel arch liners - removal and installation
• Front wing - removal and installation
• Hood - removal and installation
• Hood - fit
• Bonnet lock drive rod - removal and installation
• Bonnet lock - removal and installation
• Front door - removal and installation
• Moldings - removal and installation
• Door trim - removal and installation
• Front door window regulator - removal and installation
• Window regulator motor - removal and installation
• Door glass - removal and installation
• External door handle - removal and installation
• Door lock - removal and installation
• Outside rearview mirror - removal and installation
• Rear hinged door - removal and installation
• Rear door trim - removal and installation
• Rear door lock and switch - removal and installation. Cars with identification number 168. ** 475093 inclusive
• Gas-filled stop - removal and installation
• Central locking
• Central locking microswitch - removal and installation. Cars without remote control
• Central locking actuator - replacement
• Central locking pump - change
• Dimensions of A-class cars

Electrical system

• General description and precautions
• Additional electrical equipment - installation
• Troubleshooting electrical equipment
• Switches - check for current flow
• Relay test
• Ignition Key and remote control - battery replacement
• Opening the plug connections
• Heated rear window - check
• Sound signal - removal and installation
• Fuses - replacement
• Relay - removal and installation
• Battery - removal and installation
• Generator
• Generator - removal and installation
• Starter - removal and installation
• Traction relay - removal, installation and inspection
• Windscreen wiper
• Windshield washer jets - removal and installation
• Windshield wiper arm - removing and installing
• Front glass wiper - removal and installation
• Windshield wiper motor - removing and installing
• Rear window wiper brush holder - removing and installing
• Rear window wiper motor - removing and installing
• Washer pump motor - removal and installation
• Wiper arm angle - check and adjust
• Lighting devices
• Headlights - removal and installation
• Rear lights - removal and installation
• Instrument panel - removal and installation
• Steering column switches - removal and installation
• Cigarette lighter - removal and installation
• Switches on the center console - removal and installation
• Hazard warning light switch - removal and installation
• Outside air temperature sensor - removal and installation
• Radio receiver - removal and installation
• Speakers - removal and installation
• Roof radio antenna - removal and installation

Troubleshooting

• Identification of engine faults and their elimination
• Identification and elimination of engine cooling system malfunctions
• Possible malfunctions of the heating system, their causes and remedies
• Identification of faults in the petrol injection system and their elimination
• Determination of malfunctions of the diesel engine power system and their elimination
• Determination of malfunctions of the brake system and their elimination
• Battery troubleshooting
• Identify and troubleshoot generator faults
• List of starter malfunctions and their elimination
• Determination of fault wipers and their elimination

Basic electrical diagrams